Method for making hydrogen using a gold containing water-gas shift catalyst

ABSTRACT

The present invention relates to a method for making hydrogen comprising contacting in a water-gas shift reaction zone a feed comprising carbon monoxide and water under water-gas shift conditions with an effective catalytic amount of a catalyst comprising highly dispersed gold on a sulfated zirconia, and collecting from the water-gas shift reaction zone an effluent comprising hydrogen and carbon dioxide. The invention also provides a catalyst composition and a method of making the catalyst. A method of CO oxidation using the catalyst is also disclosed. In a specific embodiment the invention provides a method for carrying out the water-gas shift reaction in the fuel processor associated with a fuel cell.

The application is a Divisional of application Ser. No. 10/866,496, filed Jun. 10, 2004, now U.S. Pat No. 7,169,376.

BACKGROUND OF THE INVENTION

Hydrogen (H₂) is an indispensable feedstock for many petroleum and chemical processes as well as increasingly in other applications such as a fuel for Fuel Cells. Refineries in the petroleum industry, and methanol, cyclohexane, and ammonia plants in the chemical industry consume considerable quantities of hydrogen during processes for the production of gasoline, fertilizers and other chemical products. As environmental regulations demand cleaner, renewable and non-polluting processes and products, most of the hydrogen balances at petroleum refineries are becoming negative. As laws mandate lower aromatics in gasoline and diesel fuels, H₂ is now consumed in aromatic saturation and thus, less H₂ is available as a by-product. At the same time, H₂ consumption is increasing in hydro-treating units in the refineries because many of these same laws require lower sulfur levels in fuels.

Hydrogen can be obtained as a byproduct in the catalytic reforming of naphtha. In particular, significant amounts of hydrogen can be obtained during dehydrocyclization of naphtha in selective processes such as the Aromax™ process. Hydrogen is also obtained by steam reforming methane or mixtures of hydrocarbons, a reaction which produces synthesis gas which comprises hydrogen, carbon dioxide and carbon monoxide (CO). Synthesis gas represents one of the most important feedstocks of the chemical and petroleum industries. It is used to synthesize basic chemicals, such as methanol or oxyaldehydes, as well as for the production of ammonia and pure hydrogen. However, synthesis gas produced by the steam reforming of hydrocarbons does not meet the requirements for further use in some processes because the CO/H₂ ratio is too high. Therefore it is industrial practice to reduce or adjust the CO content in the syngas by conversion with steam in what is often referred to as the water-gas shift (WGS) reaction. In some instances it is desired to increase the CO content. This reaction is called the reverse water-gas shift (RWGS) reaction.

To improve H₂ yield and also the operating efficiency of carbon monoxide conversion, the water-gas shift reaction is extensively used in commercial hydrogen or ammonia plants. The reaction can be described as:

The water-gas shift reaction is usually divided into a high temperature process and a low temperature processes. The high temperature process is generally carried out at temperatures within the range of between about 350 and about 400 degrees C. The low temperature water-gas shift reaction typically takes place between about 180 and about 240 degrees C.

While lower temperatures favor more complete carbon monoxide conversion, higher temperatures allow recovery of the heat of reaction at a sufficient temperature level to generate high pressure steam. For maximum efficiency and economy of operation, many plants contain a high temperature reaction unit for bulk carbon monoxide conversion and heat recovery and a low temperature reaction unit for final carbon monoxide conversion.

Chromium-promoted iron catalysts have been used in the high temperature process at temperatures above about 350 degrees C. to reduce the CO content to about 3-4% (see, for example, D. S. Newsom, Catal. Rev., 21, p. 275 (1980)). As is known from the literature (see for example, H. Topsoe and M. Boudart, J. Catal., 31, p. 346 (1973)), the chromium, oxide promoter combines two functions. It serves to enhance catalytic activity and acts as a heat stabilizer, i.e., it increases the heat stability of magnetite, the active form of the catalyst, and prevents unduly rapid deactivation.

Unfortunately, when chromium is used, especially in hexavalent form, expenditures must be incurred to guarantee worker safety both during production and handling of the catalyst. Despite special efforts health hazards cannot be fully ruled out. In addition, the spent catalyst ultimately poses a hazard to man and the environment and must be disposed of with allowance for the government regulations relating to highly toxic waste. An example of an iron containing catalyst for this purpose that avoids the use of chromium is U.S. Pat. No. 5,830,425.

Catalysts used for the water-gas shift reaction at low temperature (or so-called low temperature shift reaction) in industry generally contain copper oxide, zinc oxide and aluminum oxide. Because these catalysts operate at relatively low temperature, they generate equilibrium carbon monoxide concentrations of less than 0.3% in the exit gas stream over an active low temperature shift catalyst. However, carbon monoxide conversion and hydrogen yield gradually decreases during normal operations as a result of deactivation of the catalyst. Deactivation can be caused by sintering and poisoning such as by traces of chloride and sulfur compounds in the feed and the hydrothermal environment of the reaction. The rate of the hydrothermal deactivation, in particular, is dependent on reaction conditions such as the temperature, the steam to gas ratio and composition of the feed gas mixture, and the formulation and manufacturing process of the catalyst.

Although copper is physically and physicochemically stabilized by both zinc oxide and aluminum oxide attempts of further stabilization of the catalyst have been made as is taught in the art. Sintering of copper crystallites is still thought to be a significant cause for deactivation/aging of the catalyst, especially when there are very low concentrations of poisons in the feed. For example, the copper crystallite size of a fresh catalyst can range from 30-100 angstroms in contrast with 100-1,000 angstroms for a discharged spent catalyst. Low temperature shift catalysts thus need to be improved with regard to both activity and stability.

Another use for hydrogen that is becoming increasingly important is as a feedstock to a fuel cell to generate electricity. The Proton Exchange Membrane (PEM) fuel cell is one of the most promising fuel cell designs and PEM fuel cells are already commercially available in limited applications. PEM fuel cells as well as several other fuel cell designs currently in development require hydrogen as a feedstock along with oxygen. Processes being considered to supply the needed hydrogen include Steam Reforming, Partial Oxidation (POX), Autothermal Reforming, and variations thereof. Most such processes for hydrogen generation also produce Carbon Monoxide (CO). Yet many Fuel Cells, in particular PEM fuel cells, cannot tolerate CO and in fact can be poisoned by small amounts of CO. The water-gas shift reaction can be used to generate additional hydrogen and convert the CO into the more inert CO₂. Many fuel cells types including PEM fuel cells can tolerate CO₂ although it can act as a diluent. Alternatively some or all of the CO₂ can be removed from the H₂ feed to the fuel cell.

Another method of removing unwanted traces of CO from a hydrogen stream is by the use of CO oxidation to form CO₂. Examples of patents that use CO oxidation for reducing the amount of CO in a reformate gas are U.S. Pat. No. 6,332,901, U.S. Pat. No. 6,287,529, U.S. Pat. No. 6,299,995, and U.S. Pat. No. 6,350,423 which are incorporated herein in their entirety.

As mentioned above one of the most common methods for the hydrogen production using hydrocarbons is the steam reforming process or variations thereof. The main process step involves the reaction of steam with a hydrocarbon over a catalyst at about 800° C. to produce hydrogen and carbon oxides. It is typically followed by several additional steps to remove impurities and carbon oxide by-products (particularly CO) as well as to maximize hydrogen production. In the water-gas shift reaction carbon monoxide reacts with steam to produce carbon dioxide and additional hydrogen. This is often done in two steps. The high temperature shift (HTS) reaction usually runs at about 350° C. and reduces CO levels to about 1%-2%. The low temperature shift (LTS) reaction runs at about 200° C. and reduces the amount of CO down to about 0.1%-0.2%. In both cases, ideally the reaction is run in an excess of steam and at the lowest temperature possible to achieve the target conversion. Conventional iron/chromium-containing HTS catalysts are inactive below about 300° C. and copper/zinc-containing LTS catalysts lose the activity above about 250° C. Both the HTS and LTS catalysts require in-situ reduction treatments and are extremely air sensitive. All currently available LTS catalysts are either pyrophoric or have a relatively low activity. Some of them are based on expensive precious metals such as Platinum (Pt), Palladium (Pd), and Rhodium (Rh). The pyrophoric nature of LTS catalysts contributes to an unacceptably rapid deactivation rate.

In the preparation of hydrogen for fuel cells, the WGS reaction zone can be the largest component of the fuel processor affecting its size, weight and performance factors such as its start-up time. Therefore, a WGS catalyst is needed which is air stable, low cost, and has high long term activity. In addition a WGS method that can operate over a wider temperature window without deactivation is needed. Furthermore a catalyst that can have high activity for WGS and/or CO oxidation is highly desired. The present invention provide such a catalyst and method.

SUMMARY OF THE INVENTION

The present invention provides a method for making hydrogen, a catalyst useful in said method and a method of making the catalyst. Accordingly, in one embodiment the present invention is directed to a method for making hydrogen comprising contacting in a water-gas shift reaction zone a feed comprising carbon monoxide and water under water-gas shift conditions with an effective catalytic amount of a catalyst comprising highly dispersed Group 1B metal such as gold on a sulfated zirconia, and collecting from the water-gas shift reaction zone an effluent comprising hydrogen and carbon dioxide. The present invention utilizes an effective amount of a catalyst comprising gold highly dispersed on sulfated zirconia and optionally promoters. A broad embodiment of the method of the present invention provides a method of converting CO, comprising:

passing a feed comprising CO, over a catalyst comprising highly dispersed gold on sulfated zirconia, at conversion conditions, to produce an effluent comprising a reduced level of CO.

The invention is also directed to a catalyst composition useful in water-gas shift reactions and/or CO oxidation reactions which comprises highly dispersed gold on sulfated zirconia. The catalyst of the present invention is particularly useful because it is non-pyrophoric and can be exposed to air without rapidly deactivating. Surprisingly, the catalyst of the present invention is also not significantly affected by moisture. The catalyst and method, of the present invention surprisingly is highly effective for both low temperature and high temperature water-gas shift reactions as well as CO oxidation. Furthermore the catalyst is highly stable and is much less prone to deactivation than prior catalyst. The low deactivation rate of the method and catalyst of the present invention is thought to be due at least in part to the sulfating. Prior WGS processes and catalysts are typically effective for either high temperature water-gas shift or low temperature water gas shift but not both. The present invention provides a method and catalyst that provides excellent CO conversion in the water-gas shift reaction over a wide range of process conditions. The excellent performance is seen at conditions comprising a surprising range of temperatures and space velocities. In one embodiment the present invention thus provides a catalyst suitable for use in a water-gas shift reaction to produce hydrogen from CO and H₂O, comprising:

-   -   (1) sulfated zirconia having, a sulfur content of between 0.02         and 1.0 wt % based on the weight of zirconia;     -   (2) gold highly dispersed in the zirconia; and     -   wherein the gold content is between 0.001 and 4.0 wt % based on         the weight of zirconia.

Among other factors the present invention provides a WGS method, a CO oxidation method, a WGS catalyst, and a method of making the catalyst that has enhanced performance over prior methods and catalysts. In particular the method and catalyst of the present invention are usable under both high temperature and low temperature shift conditions. In addition the catalyst and method of the present invention has a particularly low deactivation rate. The fact that the catalyst and method of the present invention is usable under both HT and LT shift conditions make it uniquely well suited for use in a fuel processor used for making hydrogen for use in a fuel cell. In such a fuel processor high conversion to hydrogen in the WGS reaction is required and very low levels of CO in the product hydrogen is essential. The method and catalyst of the present invention helps achieve both of those requirements—high conversion to H₂ and low levels of effluent CO.

In an embodiment of the present invention the catalyst of the present invention can be used in both high temperature shift and low temperature shift conditions in order to maximize the conversion of CO in the overall process. In this embodiment a feed comprising CO and water is passed over a catalyst comprising gold on sulfated zirconia (zirconium oxide) at high temperature water-gas shift conditions to produce an effluent having a reduced CO content. At least a portion of said effluent is passed over a catalyst comprising gold on sulfated zirconia at low temperature water-gas shift conditions to produce a second effluent comprising hydrogen and carbon dioxide.

The method and catalyst of the present invention has a number of specific embodiments. These embodiments include, for example the use of the method and catalyst of the invention in producing hydrogen by the water-gas shift reaction for use in a PEM fuel cell. In one embodiment the present invention may be used for producing hydrogen for use in a PEM fuel cell used to power a motor vehicle.

More specifically, the present invention provides a method for carrying out the water-gas shift reaction in a fuel processor associated with a fuel cell which comprises contacting in a water-gas shift reaction zone a feed comprising carbon monoxide and water under water-gas shift conditions with an effective catalytic amount of a catalyst comprising highly dispersed gold: on a sulfated zirconia, and collecting from the water-gas shift reaction zone an effluent containing a significantly reduced amount of carbon monoxide as compared to the feed.

Another embodiment of the present invention is directed at a method of making a water-gas shift catalyst, said method comprises:

-   -   sulfating a zirconium hydroxide to form a sulfated zirconium         hydroxide having a sulfate content of at least 0.1 wt % sulfate         based on the zirconium hydroxide;     -   calcining the sulfated zirconium hydroxide to form zirconia; and         depositing gold on the zirconia to form a gold loaded sulfated         zirconia having a gold content of 0.001 to 4.0 wt % and a sulfur         content of between 0.02 and 1 wt % both based on the weight of         zirconia.

As discussed above one embodiment of the present invention the water-gas shift reaction can be carried out under both HT shift and LT shift conditions. This can be done in discrete zones where one zone is at HT shift conditions and another zone is at LT shift conditions. Alternatively the water-gas shift reaction can be carried out in a zone or zones having a continuum of conditions including both HT and LT shift conditions. The catalyst and method of the present invention is particularly well suited for such a continuum because of its activity at both FT and LT water-gas shift conditions.

The present invention may be used in conjunction with several syngas generating processes including autothermal reforming, steam reforming, and partial oxidation (POX). Another embodiment of the present invention uses the method and catalyst of the presents invention in conjunction with syngas generation from a steam reformer to convert a portion of the CO produced by the steam reformer to hydrogen. In this embodiment of the present invention a desired CO/Hydrogen ratio in the effluent can be selected to suit the downstream use for the syngas. Thus the method and catalyst of the present invention can be used to achieve a desired CO/Hydrogen ratio for use in a Fischer-Tropsch process to make hydrocarbons from syngas. The catalyst described in the present invention can be used in both the water-gas shift reaction and the reverse water-gas shift reaction.

In a specific preferred embodiment of the present invention, hydrogen can be produced in a reactor or multitude of reactors that comprise an autothermal reforming zone to convert a feed comprising hydrocarbons to at least some hydrogen, water, and CO; a water-gas shift zone operating at a continuum of conditions including both HT and LT shift conditions where the water and CO are converted at least in part to hydrogen and CO₂; and a oxidation zone where remaining CO is oxidized to CO₂ to achieve a product comprising hydrogen containing low levels of CO suitable for use in a fuel cell.

In another embodiment of the present invention, the catalyst of the present invention can be used in an oxidation zone where CO is oxidized to CO₂. The catalyst of the present invention has been shown to be effective in CO oxidation as is shown in the examples below. In this embodiment CO in the presence of oxygen can be oxidized to form CO₂ by passing a first feed comprising CO and a second feed comprising oxygen, in an oxidation zone, over a catalyst comprising highly dispersed gold on sulfated zirconia, at oxidation conditions, to produce an effluent comprising a lower level of CO then in the feed. Although not to be limited, this embodiment can be very effective and useful in removing unwanted traces of CO from hydrogen containing streams for uses such as in a PEM fuel cell. An example of a process where the catalyst and process of the present invention can be used to remove CO from a hydrogen containing stream is U.S. Pat. No. 6,682,838 which is incorporated by reference in its entirety,

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows the performance of novel Au calcined sulfated zircona catalyst at 240 C.

FIG. 2 shows the performance of noval Au calcined sulfated zircona catalyst at 20,000 GHSV.

FIG. 3 shows the performance of noval Au calcined sulfated zircona catalyst a range of temperatures and space velocities.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a novel catalyst for the Water-Gas Shift reaction, a method for preparing this catalyst and a method for conducting the water-gas shift reaction in the presence of this catalyst. The catalyst of this invention shows substantially higher activity and stability when compared to other catalysts. The catalyst of the present invention comprises highly dispersed Group 1B metal on a crystalline sulfated zirconia support optionally in association with modifiers and additives such as, for example Group I, Group II and rare earth oxides.

Surprisingly we have discovered that unusually active and stable WGS catalysts can be prepared when sulfated zirconia is used for the catalyst preparation. The presence of sulfate is critical for making the catalyst of the present invention with its outstanding performance. In a preferred embodiment of the catalyst of the present invention it has been found that the sulfur level should be at least 0.02 wt % based on the weight of zirconia (also referred to as zirconium oxide or ZrO₂). Preferably the sulfur level of the catalyst should be between 0.02 and 4.0 wt % based on the weight of zirconium oxide, more preferably between 0.02 and 3.5 wt %, still more preferably between 0.02 and 2.5 wt % and most preferably between 0.02 and 1 wt % based on the wt of the zirconium oxide.

We have further discovered that the catalyst of the present invention can operate in what is considered to be high temperature shift range down into the low and even ultra low temperature range. Thus the process of the present invention when using the novel catalyst of the invention is able to operate over a temperature range from about 100 degrees C. to about 500 degrees C.

In a typical preparation, the catalysts of this invention are prepared by an aqueous gold deposition onto a calcined sulfated zirconia support. This is usually followed by drying in air at around ambient temperature or slightly higher, e.g. about 35° C. Prior to use the catalyst is generally activated in the reactor under nitrogen at 250° C. for about 2 hours.

Not wishing to be bound by any particular theory we believe that it is extremely important to keep Group 1B metal from reducing to a zero valence metal state during the Group 1B metal deposition process. Also it is believed that the sulfated zirconia support plays a critical role in keeping gold well dispersed. Additionally it is believed that it is advantageous for at least some of the zirconia to be in the tetragonal phase.

As discussed above a highly dispersed Group 1B metal is an essential feature of the catalyst used in the present invention. The Group 1B metals are Gold, Silver and Copper, in a preferred embodiment of the present invention the highly dispersed Group 1B metal should be Gold. In another embodiment of the present invention a: mixture of Group 1B metals can be used. Preferably the mixture of Group 1B metals includes at least some Gold.

In a preferred embodiment of the present invention a majority of the zirconia in the catalyst should be in the tetragonal phase, more preferably the zirconia should be predominately in the tetragonal phase. The phase of the zirconia can be determined by the PXRD (Powder X-Ray Diffraction) pattern of the catalyst sample The X-ray diffraction pattern can be used to determine the phase of the zirconia due to the different phases exhibit characteristic lines in the pattern.

It was demonstrated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM) that the catalysts of this invention most preferably have no detectable gold particles after gold deposition and drying steps. In the catalyst and method of the present invention the gold loading of the catalyst should be at least 0.001 wt % based on the weight of zirconium oxide in the catalyst. Preferably the gold loading of the catalyst should be between 0.001 and 5.0 wt %, more preferably between 0.001 and 4.0 wt %, still more preferably between 0.01 and 3.0 wt % , even more preferably between 0.1 and 3.0 wt %, and most preferably between 0.1 and 2.0 wt % based on the weight of zirconium oxide in the catalyst. When silver or copper are used in the catalyst either alone or in combination with gold higher levels may be required than gold alone to achieve the same level of catalytic activity.

Another important feature of the catalyst of the present invention is that the gold be very highly dispersed on the catalyst. The methods for gold loading described in the Detailed Description of the Present Invention and in the Examples can lead to a very highly dispersed catalyst. Activation conditions must also be carefully selected to avoid agglomeration of the gold (or other Group 1B metal) and loss of the very high dispersion. It is preferred that at least 80 wt % of the gold be dispersed in particles of less than 10 angstroms when measured by TEM. More preferably at least 90 wt % of the gold should be dispersed in particles of less than 10 angstroms when measured by TEM. Most preferably there should be no detectable gold particles on the catalyst after gold deposition and drying steps when examined by TEM and SEM. In the present application the phrase no detectable gold particles means essentially no particles having an approximate diameter above about 7 to 9 angstroms.

There is a trade off between the amount of surface area and stability of the sulfated zirconia support. So it is important that the zirconia surface area of the sulfated zirconia support be carefully controlled. The BET (Brunauer, Emmett, Teller) surface area of the sulfated zirconia support should be at least 5 m²/g, preferably at least 10 m²/g, more preferably between 10 and 500 m²/g, still more preferably between 30 and 250 m²/g and most preferably between 50 and 100 m²/g. The BET surface area can be determined using ASTM D 4567 (volume 5.03) or ASTM D 3663 which are incorporated herein by reference.

As mentioned above it is also critical to the present invention that the catalyst comprise sulfated zirconia. It has been found that by employing the sulfated catalyst described above that the method of the present invention displayed surprisingly low, deactivation rates. Methods for making a sulfated zirconia material suitable for use as a starting material in the preparation of the catalyst of the present invention can be found in U.S. Pat. Nos. 6,448,198 and 6,180,555 which are incorporated herein in their entirety.

In addition to the sulfated zirconia, the catalyst of the present invention optionally can include an additional structural support material such as a refractor metal oxide material such as for example silica, alumina, magnesia, titania, etc. and mixtures thereof. The structural support can be in any form including for example monolith, spheres, or hollow cylinders. More specifically the structural support material can additionally include “supports” such as alumina, silica, silica-alumina, silicate, alumino-silicate, magnesia, zeolite, active carbon, titanium oxide, thorium oxide, clay and any combination of these supports. In one embodiment of the present invention preferably, the invention's catalyst can contain between, 50% and 95% by weight or structural support, on which 5% to 50% of sulfated zirconia by weight is deposited.

In the method of the present invention the catalyst has been found to be effective at a surprisingly broad range of temperatures. In the method of the present invention the water-gas shift reaction can be carried out between 100 and 500° C. preferably between 135 and 420° C. It is understood by one of skill in the art that as catalysts become less active the reaction temperature may be increased to achieve a target conversion. However, increasing temperatures leads to an increased concentration of CO due to a shift in equilibrium.

Space velocities useable in the method of the present invention as measured by gas hourly space velocity (GHSV) are between 1000h⁻¹ to 200,000h⁻¹, preferably between 10,000h⁻¹ to 100,000h⁻¹, more preferably between 25,000h⁻¹ to 100,000h⁻¹. It is understood by one of skill that the space velocity can be decreased to compensate for lower activity.

As mentioned above in one embodiment of the present invention the method can optionally include a CO oxidation zone in order to reduce the level of CO in the H₂ such that it is suitable for use in a fuel cell such as a PEM fuel cell. A potential advantage of the present invention is that the WGS method of the present invention can be used to convert most of the CO while also making hydrogen and leaving only a small amount or trace amount of CO to be oxidized in the CO oxidation zone. This means that the CO oxidation zone can be smaller in size and can further reduce the size and complexity of a fuel processor system. Under some circumstances the CO oxidation zone may be eliminated entirely. An example of a fuel processor that includes a combination partial oxidation/steam reforming zone, WGS zone, and CO oxidation zone is shown in U.S. Pat. No. 6,521,204 which is incorporated herein in its entirety.

Alternatively the present invention provides a catalyst and method for CO oxidation. As discussed above CO oxidation can be used to remove the last traces of CO to achieve a H₂ stream containing very low levels of CO. The CO oxidation method and catalyst of the present can be used in conjunction with the WGS method and catalyst or can be used independently.

EXAMPLES Example 1 Preparation of a Sulfated Zirconia Base Material

This example shows the preparation of a mass sulfated zirconia material that can be used as a base for the catalyst of the present invention. 35 g of ZrO(NO₃)₂, 6H₂O is dissolved in 350 ml of distilled water with agitation. Zirconium hydroxide gel is precipitated by adding 17 ml of a 28% ammonia solution while agitating. The final pH is about 8.5. After filtering and washing until a pH 7 (redispersal in 350 ml of water), the gel is dried overnight at 120 degrees C. The result is about 13.8 g of a solid. The sulfation is done by adding 85 ml of sulfuric acid (1 N), by static contact for 15 minutes. The sulfated zirconia is then spun dry. Then the material is dried overnight at 120 degrees C.

Example 2 Preparation of Sulfated Zirconia on an Alumina Support

This example shows the preparation of a structurally supported sulfated zirconia base that can be used in the catalyst of the present invention. The catalyst sample is prepared starting from 25 g of an alumina support, marketed by AKZO under the name CK 300, previously calcined at 600 degrees C. The zirconium deposition is done in a ball by impregnating the support with a solution formed by the dissolution of 3.48 g of zirconyl chloride (ZrOCl₂, 8 H₂O, marketed by Prolabo also available from Aldrich) and 0.46 g of NH₄Cl in 11 cm³ of distilled water, with a volume corresponding to the porous volume of the support. The solid obtained is first dried overnight at 120 degrees C. then calcined for 2 hours at 650 degrees C. This operation is repeated twice (deposit of zirconium three times), then the solid obtained is calcined for 4 hours at 750 degrees C. Thereafter, the sulfation of the zirconium deposited on the surface of the alumina support takes place by circulating 162 cm³ of a sulfuric acid solution (5 N) at room temperature for 1 hour. Then the solid is spun-dry then allowed to dry overnight at 120 degrees C. Next it is calcined for 2 hours at 500 degrees C. in a flow of dry air at 60 liters per hour.

Example 3 Preparation of Calcined Sulfated Zirconia

A sample of sulfated zirconium hydroxide powder containing about 2% wt of sulfate was calcined in air at 660° C. according to the following procedure. Sulfated zirconium hydroxide can be obtained from commercial sources such as Aldrich. The sample was heated up to 660° C. slowly over 10 hours and kept at this temperature for 6 hrs, followed by slow cooling to ambient temperature. The nitrogen BET (Brunauer, Emmett, Teller) surface area of the powder before the calcinations was found to be 284 m²/g and after the calcinations it was 75 m²/g. The starting powder was amorphous by Powder X-Ray Diffraction (PXRD). The PXRD pattern of the calcined material was that of the tetragonal phase of zirconia containing a small amount of the monoclinic phase.

Example 4 Preparation of Gold on Calcined Sulfated Zirconia Catalyst (Gold Addition)

The gold was deposited on the calcined sample from Example 3 by first preparing a solution of 0.34 g of HAuCl₄×3H₂O in 600 ml of distilled water and then heating the solution to about 60° C. The acidity of the solution was adjusted to pH 8.6 by the addition of a 1.0 M sodium carbonate solution. 6 g of the calcined sulfated zirconia sample was added to the solution and stirred for 2 to 3 hrs by slow rotation in a rotary evaporator. The resulting solid was removed by filtration and dried in an air convection oven at 35° C. overnight. Finally the dry powdered sample was pressed and sized to −18/+40 (US) mesh for the reactor testing. The resulting catalyst had a nitrogen BET surface area unchanged of about 75 m²/g. The PXRD pattern of the gold deposited sample showed both tetragonal and monoclinic phases of zirconia present in almost equal amounts. Elemental analysis results for various samples prepared by the above procedure showed that the amount of sulfate decreased to about 0.26% wt, and the gold loading were in the range of 1% wt. to 2% wt.

Example 5 Gold Deposition Using a Reduced Amount of Water

The gold was deposited on the calcined sample from Example 3 by first preparing a solution of 0.20 g of HAuCl₄×3H₂O in 60 ml of distilled water and then heating the solution to about 6000. The pH of the solution was adjusted to values between 9 and 10 by the addition of a 1.0 M sodium carbonate solution, 6 g of the calcined sulfated zirconia sample was added to the solution and stirred for 2 to 3 hrs by slow rotation in a rotary evaporator. The resulting solid was separated by filtration, rinsed with 100 ml of distilled water and dried in an air convection oven at 35° C. overnight. Finally the dr powdered sample was pressed and sized to −18/+40 (US) mesh for the reactor testing.

Example 6 Near Incipient Wetness Impregnation

The catalyst of this invention can also be prepared by near incipient wetness impregnation procedures of a gold compound on the sulfated zirconia support.

Methods of Near Incipient Wetness Impregnation are taught in the art.

Example 7 Performance of the Gold-Sulfated Zirconia Catalyst

2 cc of the catalyst from Example 2 was diluted with 6 cc of acid-washed alundum of the same size and loaded into a ½″ O.D. stainless steel tube reactor. The catalyst bed was held in place with alundum and glass wool plugs on both ends. The catalyst was heated to up 250° C. at a rate of 50° C./h in a 200 sccm flow of nitrogen overnight and then cooled to a test temperature.

The catalysts were tested in the temperature range of 135° C. to 420° C. at space velocities of 2000h⁻¹ to 50000h⁻¹ based upon the volume of catalyst. Two different gas mixtures were used in the testing. The gas mixtures were produced either by blending four syngas components—CO, H₂, N₂ and CO₂ in a manifold or by using a mixture of a predefined composition. Water was introduced to the gas stream as vapor produced by heating the stream of liquid water in a small flash vessel just below the boiling point of water at the reactor pressure. For example, for the reaction mixture of the following composition −11% vol. CO, 25.6% vol. H₂, 68% vol. CO₂, 31.1% vol. N₂, 25.4% vol. H₂O, at 20,000 GHSV, 200° C. and 30 psig the catalyst had constant activity at equilibrium CO conversion of about 98.2% for the time it had been tested of about 350 hours. At the same conditions but at a temperature of 350° C. the catalyst operated at constant activity and equilibrium conversion of about 86.1%. The results of catalyst performance at 240° C. over a range of space velocities for the reaction mixture composition of 4.65% vol. CO, 34.31% vol. H₂% 7.43% vol. CO₂, 13.73% vol. N₂, 36% vol. H₂O are shown in FIG. 1. The changes of the catalyst activity with temperature at 20,000 GHSV are shown in FIG. 2 and over a range of space velocities art different temperatures in FIG. 3 for this same gas mixture. Finally, for both reaction mixtures it was demonstrated that the catalyst could: be cooled down to an ambient temperature in air, then heated back to a reaction temperature and restarted without loss of activity repeatedly.

Example 8 Startup—Shutdown Cycle Performance

The catalyst from Example 2 was tested for effects of the feed mixture, in particular water, during temperature shutdown on catalyst performance. Initially, the reactor run was started according to the procedure in the previous example using the feed mixture containing 11% vol. CO, 25.6% vol. H₂, 6.8% vol. CO₂% 31.1% vol. N₂, 25.4% vol. H₂O, at 200° C. and 30 psig. After the stable CO conversion was attained the heat to the reactor was turned off and the reactor was allowed to cool under the feed to ambient temperature. It was kept at these conditions for 1 hr followed by reheating of the reactor to 200° C. under 200 sccm of nitrogen and re-introduction of the feed mixture. After the stable CO conversion was attained the procedure was repeated. For this particular experiment after ten cycles the CO conversion remained unchanged at about 73% at 10,000 GHSV. This example demonstrates that the exposure of the catalyst to condensed water vapor does not affect significantly it's reactor performance.

Example 9 Performance of the WGS Catalyst in the Presence of Air

The catalyst of Example 2 Was tested for effects of oxygen in the feed mixture. The reactor run was started according to the procedure in the previous example using the feed mixture containing 11% vol. CO 25.6% vol. H₂, 6.8% vol. CO₂, 26.1%, vol. N₂, 5.0% vol. O₂, 25.4% vol. H₂O, at 200° C. and 30 psig. The catalyst was run at these conditions for about 40 hours at average CO conversion of 98%. No significant loss of hydrogen was observed.

Example 10 Performance of the Gold-Sulfated Zirconia Catalyst in CO oxidation

2 cc of the catalyst from Example 2 was diluted with 6 cc, of acid-washed alundum of the same size and loaded into a ½″ O.D. stainless steel tube reactor. The catalyst bed was held in place with alundum and glass wool plugs on both ends. The catalyst was heated to up 250° C. at a rate of 50° C./h in a 200 sccm flow of nitrogen overnight and then cooled to a test temperature.

The catalyst was tested for CO oxidation activity by introducing to the reactor a CO/air feed at the ratio of 2 to 3 at 6000 h⁻¹ GHSV at room temperature. The temperature in the reactor increased to about 150° C. when oxygen conversion approached 100% and stabilized. No decline in CO conversion was observed over 120 hrs operation. In the same experiment the feed to the reactor was switched back and forth between the CO/air mixture and the typical WGS feed as in Example 8. At 20000 h⁻¹ GHSV, 200° C. and 30 psi the CO conversion remained on average at about 98%. This example clearly demonstrates that the same catalyst is very active catalyst for both WGS and CO oxidation reactions.

Comparative Example 11 Preparation of Gold on Zirconia Catalyst in the Absence of Sulfate

A sample of gold on zirconia was prepared as follows, 0.33 g of HAuCl₄×3H₂O was added to 600 ml of deionized water then heated to 60 degrees C. The pH was adjusted by dropwise addition of 1N Na₂CO₃ until the solution cleared. The final pH was 8.55. 3.09 g of zirconium IV oxide extrudate was placed in a round bottom flask along with the gold containing solution. The flask was placed on a rotory evaporator and immersed in a bath that was maintained at 60 degrees C. The flask was allowed to rotate for 2 hours 10 minutes. The extrudate was then filtered from the solution. The extrudate had maintained their shape and rigidity after filtering. The extrudate was dried.

Comparative Example 12 Performance of Gold on Zirconia Catalyst in the Absence of Sulfate

1.5 cc (1.7) of the Au on zirconia catalyst formed in Comparative Example 7 was loaded into a WGS tube reactor. The sample was first diluted with 6.5 cc of acid-washed 24/48 alundum and loaded into the ½″ OD stainless steel tube reactor. The catalyst bed was held in place with alundum and glass wool plugs on both ends. The reactor was heated to 200 degrees C. with a N₂ flow rate of 200 cc/min. The temperature was held at 200 degrees C. for 1 hour then the Syngas mixture was introduced as the feed. The pressure was raised to 30 psig and the Syngas flow rate was set at 80.0 cc/min. H₂O was injected at a flow rate of 0.0165 ml/hr to achieve a space velocity of 4000 hr⁻¹. The process achieved a CO conversion initially of as much as 85%. However at constant temperature (200 degrees C.) after 10 hours the conversion declined to about 72% and after 20 hours to about 64%.

Example 13 Performance of Au on Sulfated Zirconia Catalyst

2.0 cc (2.45 g) of Au on sulfated zirconia catalyst was loaded into a WGS tube reactor. The sample was first diluted with 6.0 cc of acid-washed 24 mesh alundum and loaded into the ½″ OD stainless steel tube reactor. The catalyst bed was held in place with alundum and glass wool plugs on both ends. The reactor was heated to 200 degrees C. with a N₂ flow rate of 200 cc/min. The temperature was held at 200 degrees C. for 1 hour then the Syngas mixture was introduced as the feed. The pressure was raised to 30 psig and the Syngas flow rate was set at 80.0 cc/min. H₂O was injected at a flow rate of 0.0165 ml/hr to achieve a space velocity of 4000 hr⁻¹. The process achieved a CO conversion initially of as much as 96%. After 20 hours of operation the conversion was at about 95%. This example shows that the Au on sulfated zirconia achieves better conversion and better stability than unsulfated Au on zirconia catalyst (see comparative example 12) at the same process conditions. 

1. A method of making a catalyst, comprising: a) sulfating a zirconium hydroxide to form a sulfated zirconium hydroxide having a sulfate content of at least 0.1 wt % sulfate based on the zirconium hydroxide; b) calcining the sulfated zirconium hydroxide to form sulfated zirconia; and c) depositing gold on the sulfated zirconia to form a gold loaded sulfated zirconia having a gold contents of 0.001 to 3.0 wt % and a sulfur content of between about 0.02 and about 1 wt %.
 2. The method according to claim 1 wherein the sulfated zirconia is predominantly in the tetragonal form.
 3. The method of claim 1, wherein the depositing gold on the sulfated zircona is done by an aqueous gold deposition.
 4. A catalyst, comprising: (1) sulfated zirconia having a sulfur content of between about 0.02 and about 1.0 wt % based on the weight of zirconia; (2) highly dispersed gold; and wherein the gold content is between about 0.001 and about 3.0 wt % based on the weight of zirconia.
 5. The catalyst of claim 4, wherein the highly dispersed gold comprises at least 80 wt % gold particles of less than 10 angstroms when measured by TEM. 